Snowmobile

ABSTRACT

The present invention generally relates to snowmobiles. More particularly, the present invention relates to the components of a snowmobile such as the frame, running boards and various other assemblies.

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/302,394, filed on Feb. 8, 2010, and U.S.Provisional Patent Application Ser. No. 61/337,676, filed on Feb. 9,2010, the complete disclosures of which are expressly incorporated byreference herein.

BACKGROUND

The present invention generally relates to snowmobiles. Moreparticularly, the present invention relates to the components of asnowmobile such as the frame, suspension, running boards and variousother assemblies.

Generally, there are a variety of configurations of snowmobilesavailable for applications such as deep snow, high performance, luxurytouring, trail riding, etc. Most snowmobiles include a frame, a powertrain, a pair of front skis, and an endless belt assembly. Typically,features such as engine displacement and track length vary dependingupon the specific application for which the snowmobile is targeted. Forexample, snowmobiles designed primarily for deep snow application mayinclude an endless belt assembly having a longer track length, i.e. 166inches (4.2 meters), than a snowmobile designed primarily for trailriding, i.e. 135 inches (3.4 meters). A snowmobile designed for deepsnow may also include a relatively large displacement engine, i.e. 900cc³ (54.9 inches³), to provide suitable power when operating in amountain environment at higher elevations with less oxygen. Otherfeatures of a deep snow snowmobile may be added to improve ride andhandling characteristics such as side hilling.

A deep snow snowmobile is shown in our patent application Ser. No.11/501,454 filed Aug. 9, 2006, the contents of which are incorporatedherein by reference.

SUMMARY

One illustrative embodiment of the present invention includes asnowmobile comprising a frame, a power train supported by the frame; arunning board assembly supported by the frame and comprising a toe clip,a front wall and a foot tread; and a shroud laterally encompassing thetoe clip and the back wall, with the toe clip extending rearwardly,beyond a rear edge of the shroud.

Another illustrative embodiment of the present invention includes aframe; a power train supported by the frame; a running board assemblysupported by the frame and comprising a toe clip, a front wall and afoot tread; and a shroud laterally encompassing the toe clip and theback wall, with the back wall extending substantially aligned with arear edge of the shroud.

Another illustrative embodiment of the present invention includes asnowmobile comprising: a frame; a power train supported by the frame;and a running board assembly supported by the frame and comprising a toeclip, a front wall and a foot tread; the foot tread having upturnedembossed openings having gripping surfaces thereon.

Another illustrative embodiment of the present invention includes asnowmobile comprising a frame; a power train supported by the frame; anda running board assembly supported by the frame and comprising a toeclip, a front wall and a foot tread; the foot tread having upturnedembossed openings and openings through the running board.

Another illustrative embodiment of the present invention includes asnowmobile comprising a frame; a power train supported by the frame; arunning board assembly supported by the frame and comprising a toe clip,a front wall and a foot tread; and a shroud laterally encompassing thetoe clip and the back wall, with the back wall extending substantiallyaligned with a rear edge of the shroud.

The above mentioned and other features of this invention, and the mannerof attaining them, will become more apparent and the invention itselfwill be better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an illustrative embodiment of asnowmobile;

FIG. 2 is a rear perspective view of the embodiment shown in FIG. 1;

FIG. 3 is a side view of the left hand side of the embodiment shown inFIG. 1;

FIG. 4 is a side view of the right side of the embodiment shown in FIG.1;

FIG. 5 is a top view of the embodiment shown in FIG. 1;

FIG. 6 is a front view of the embodiment shown in FIG. 1;

FIG. 7 is a rear view of the embodiment shown in FIG. 1;

FIG. 8 is a bottom view of the embodiment shown in FIG. 1;

FIG. 9 is an enlarged view of the running board assembly of theembodiment shown in FIG. 1;

FIG. 10 is an enlarged view of the foot tread of the embodiment shown inFIG. 1;

FIG. 11 is an enlarged side view of a front portion of the runningboard;

FIG. 12 is an exploded view of the tunnel;

FIG. 13 is an enlarged view of the rear snow flap;

FIG. 14 is a partial front perspective view of the snowmobile with thefront body removed;

FIG. 15 is an enlarged front perspective of the front frame;

FIG. 16 is a front perspective of the cast frame member;

FIG. 17 is an underside perspective view of the cast frame member ofFIG. 16;

FIG. 18 is a rear view of the cast frame member;

FIG. 19 is a front perspective view of the steering assembly;

FIG. 20 is a side view of the steering assembly mounted to the castframe member of FIG. 16;

FIG. 21 is a side perspective view of a heat shield member mounted to aninside of the body panel; and

FIG. 22 is an exploded perspective view of the air intake system;

FIG. 23 is a side showing the suspension system removed from the tunnel;and

FIG. 24 shows an exploded view of a rear bumper.

DETAILED DESCRIPTION

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of the present invention, the drawings are not necessarilyto scale and certain features may be exaggerated in order to betterillustrate and explain the present invention.

The embodiments disclosed below are not intended to be exhaustive or tolimit the invention to the precise forms disclosed in the followingdetailed description. Rather, the embodiments are chosen and describedso that others skilled in the art may utilize their teachings. Forexample, while the following description refers primarily to asnowmobile, it should be understood that the principles of the inventionapply equally to other snow vehicles. While the present inventionprimarily involves a snowmobile, it should be understood, however, thatthe invention may have application to other types of vehicles, such asmotorcycles, ATVs, utility vehicles, scooters, and mopeds.

Referring to FIGS. 1-8, one illustrative embodiment of a snowmobile 10is shown. Snowmobile 10 includes a frame 12, supported by front skis 14and by endless belt assembly 16. Front skis are coupled to a frontsuspension 18, and endless belt assembly is supported by a rearsuspension 20. Snowmobile also includes a seat assembly 22, front outerbody 24, and a steering assembly 26. Steering assembly 26 is operablycoupled to steering arms 28 (FIG. 2) which allows a rider to steersnowmobile 10. A power train is covered by outer body 24 and providespower to endless belt assembly 16. Running board assemblies 32 extendalong the sides of the seat assembly which are supported by the frame12. A snow flap 34 (FIG. 2) is also supported by the frame rearward ofthe endless belt.

With reference to FIGS. 1 and 2, frame 12 includes a tunnel 40 having atop wall 42 and side walls 44. As shown best in FIG. 2, endless belt 16at least partially runs up into tunnel 40 between side walls 44 andupwardly towards top wall 42. As shown, running board assemblies 32include a rider's foot grip assembly 50 (FIG. 4) and a foot treadassembly 52, where the foot grip assembly 50 and foot tread assembly 52are supported by the tunnel sidewall 44. As shown best in FIGS. 11 and12, the tunnel 40 also include a plurality of cutout portions 46 whichreduce the material in locations where fasteners are not needed. Thesecutouts 46 help to reduce the weight of the entire vehicle. The surfaceto which sidewalls 44 abut (not shown), also include notches butcomplement notches 46 such that the notches do not overlap. Othercutouts could be provided elsewhere as well.

With reference now to FIG. 9, the foot grip assembly 50 is shown ingreater detail. Foot grip assembly 50 includes frame member 100 whichextends over the top wall 42 of tunnel 40, having a first portion 102extending downwardly and away from the tunnel, and a second portion 104extending downwardly and reversely bent towards the tunnel. The end ofportion 104 is flattened and includes a flange at 106. Foot gripassembly 50 further includes a tube portion 110 which is fastened to theside of the tunnel and connected to frame portion 100 for example, bywelding. A toe clip 112 extends between frame member 110 and frameportion 102. Finally, foot grip assembly 50 includes a back wall 114attached at marginal edges 115 and 116, and comprises plural slottedopenings 118.

With reference to FIGS. 9-12, foot tread assembly 52 is comprised of anelongate frame member 122 and running board plate 124. Elongate framemember 122 is comprised of a tube 126 and a frame bracket 128. As shownin FIG. 12, frame bracket 128 is discreet from tube 126. Bracket 128includes a bracket foot 130 which extends into tube 126 and a bracketarm 132 for attachment to flange 106. Bracket foot 130 may be attachedto tube 126 by way of fasteners, welding or adhesives, or a combinationthereof. As shown (FIG. 9), the flattened surfaces of flanges 106 andbracket arms 132 are positioned back to back and attached by way offasteners 134 (FIG. 9). Furthermore, the planes of the flat surfaces offlanges 106 and bracket member 132 extend in a longitudinal direction asdescribed herein.

With respect now to FIGS. 9 and 10, running board plate 124 is comprisedof a plate portion 140 having a lip 142 positioned and attached toelongate tube member 126 as shown. The opposite side of the plateportion 140 has a marginal edge 144 which is attached to the tunnel sidewall 44. As shown in FIG. 12, the running board plate 124 is integralwith the tunnel side wall 44, however this connection could also be byfastening, such as by welding, adhesives or riveting.

The running board plate 124 further includes a plurality of upturnedembossments 150 (FIG. 10) having a generally triangular shape withgripping serrations 152 positioned thereon. Intermediate each of theupturned embossments 150 is an opening 156, of reverse triangular shape,where the embossments 150 rigidify the plate portion 140 whereasopenings 156 maximize the open area of the foot tread to allow snow todrop downwardly therethrough. This provides a smooth bottom surface toplate portion 140, having no interference with the snow.

Thus, as shown in FIG. 9, an enlarged ventilation area is defined by thespacing at 160 and within the slots 118. The longitudinal disposition ofthe flanges 106 and 132 as described above also maximizes theventilation area 160, particularly for the removal heat from the enginecompartment as described herein.

Finally, with respect to FIGS. 9-11, an outer shroud 180 covers footgrip assembly 50 and includes a shroud portion 182 which encompassesportions 102 and 104 of frame tube 100. Shroud 180 also includes a rearedge 184 (FIG. 11) which is proximate to back wall 162. As shown best inFIG. 11, toe clip 112 extends rearwardly beyond rear edge 184 of shroud180 which provides easy access for the rider to place their boot in thetoe clip, yet prevents forming a pocket into which snow may accumulateand pack. Also, the forward angle of edge 184 allows a rider's foot toposition sideways, overlapping the foot tread assembly 52, and yet stayretained behind foot grip assembly 50.

With reference now to FIG. 13, snow flap 34 is shown in an enlargedview. Snow flap 34 is hingedly mounted to the tunnel 40 along a rearedge 190. The snow flap 34 includes a plurality of apertures 192 whichreduces the overall weight of the component. These could be machined ormolded in.

With reference now to FIG. 14, the outer body 24 has been removed whichbetter exposes the engine compartment 200, the steering assembly 26, theframe front portion 202, and the power train 204. The power train 204includes an engine 206 having an exhaust system 208, an intake system210 and a drive system including a CVT 212. As mentioned above, theventilation area 160 was defined around the foot grip area, and thisallows the CVT ventilation to exhaust through ventilation area 160.

With reference now to FIG. 15, the front portion 202 of the frame isshown in greater detail. Front portion 202 includes a cast coupling orconnector 220 configured to attach plural frame tubes, namely frontframe tubes 222, 224 and rear frame tubes 226 and 228 thereto. The frametubes 222, 224, 226, 228 may be attached to the cast coupling 220 by wayof fasteners such as 230 and/or may be adhesively fixed to the castcoupling 220. As shown, the cast coupling 220 further includes twosupport webs 232 and 234. Each of the webs is provided with threadedapertures, for example, 236 and 238. As also shown in FIG. 15, asteering post 260 of steering assembly 26 is directly coupled to webs232 and 234 of the cast coupling 220, as described herein.

With reference now to FIGS. 16-18, cast coupling 220 will be describedin greater detail. Cast coupling 220 further includes a first circularchannel (FIG. 16) defined by portions 240 and 242 having threaded bosses244 extending downwardly therethrough. A second circular channel isdefined by portions 246 and 248 having threaded bosses 250 therein. Thecircular channels are intersected by cylindrical members 252 and 254.Thus, with a comparison of FIGS. 15 and 16, it should be appreciatedthat frame tubes 222 and 224 are positioned across the circular channelswith fasteners such as 230 positioned through the frame tubes 222, 224and into the threaded bosses 244, 250. Adhesive may also be applied.Meanwhile, frame tubes 226 and 228 are positioned in the cylindricalmembers 252 and 254, and may also be fixed in place by way of fastenersand adhesive.

With reference now to FIG. 18, cast coupling 220 includes machinedmounting surfaces 232A and 234A on the backside of the webs 232 and 234,respectively, for mounting the steering post as described below. Finallyas best shown in FIG. 17, cast coupling 220 includes an integral fueltank mounting tab shown at 258.

With reference now to FIG. 19, the steering assembly is shown in greaterdetail. As shown, steering post 260 includes an upper and lower bearingposts 270 and 272 which attach to the backside of the webs 232, 234respectively, with fasteners being attached to threaded apertures 236and 238, respectively. This rigidly connects the steering post 260 tothe cast coupling 220 yet allows the steering post to pivot about thecorresponding bushings 270 and 272. As also shown, handlebars 276 ofsteering assembly 26 are attached to the steering post 260 by way of aclamp at 278.

Steering assembly 26 further comprises a lower steering post 280 whichis operatively coupled to steering post 260 by way of respective linkarms 282, 284, connected together by way of a link 286. Lower steeringpost 280 is ultimately connected to steering arms 28 by way of a furthersteering arm, not shown, to maneuver the steering skis 14.

With reference now to FIG. 20, steering assembly 26 is shown mounted tothe backside of cast coupling 220 with the bushings 270, 272 (FIG. 19)mounted to the surfaces 232A, 234A (FIG. 18), respectively. As shown,steering post 260 is nearly vertical and could be in the range whereangle θ could be between 0 and 15 degrees and as shown is about 13degrees. As steering post 260 is positioned at a substantially uprightangle, the ergonomics is improved for the deep snow rider.

As known, when side hilling, a rider is often standing on only one sideof the running board assemblies 32 and the maneuverability of thesteering post and handlebars 276 is substantially increased when thesteering post 260 is close to vertical. This prevents the handlebars 276from dipping down or raising up on either side when attempting to steerthe snowmobile while standing on only one side.

FIG. 20 also shows a fuel tank 258 having a front end positionedadjacent to the integral fuel tank mounting tab 256 to retain a frontend of the fuel tank 258. Fuel tank 258 may be attached to tab 256through fasteners, or fuel tank could have a molded slot to be appliedover tab 256.

With respect now to FIG. 21, front side panel 300 (see also FIG. 4) onthe right hand side of the snowmobile is provided with sound insulation302 as well as a heat shield 304. The foam includes a front surface 306,a back surface 308, and a plurality of cutouts 310 extending between thefront and back surface. Heat shield 304 includes a plate 320 having aplurality of mounting feet 322 which correspond in location to theapertures 310. An adhesive is provided against the back surface 308 toretain sound insulation to the inside surface of the panel 300. Heatshield 304 can be placed with the feet 322 aligned with the associatedapertures 310 and pressed against the foam 302 until the feet contactthe adhesive, through the apertures, which retains the heat shield tothe foam member 302. This prevents any fasteners or additionaldimensional requirements for attaching the heat shield to the foam. Thisalso provides less weight for the snowmobile yet provides a heat shield304 adjacent to a portion of the exhaust system of the snowmobile powertrain as described above. The adhesive could be a double-sided stickytape, double sided foam tape, or any other adhesive for the purposeddescribed.

Referring now to FIG. 22, air inlet 210 (FIG. 15) is shown in greaterdetail as comprised of inlet housing 350, retainer housing 352 andsound-deadening foam 354. Housing 350 is generally rectangular having aplurality of apertures 356 extending therethrough, where the rectangularhousing has a front wall 360, sidewall 362 opposite side wall 366 andrear wall 368. Retainer 352 includes a front wall 370, sidewall 372having lugs 374, opposite sidewall 376 and a partial rear wall 378.Sound-deadening foam 354 generally includes a foam body portion 380having locating apertures at 382.

It should be appreciated that the foam 354 is positioned on an inside ofthe retainer member 352 with lugs 374 aligned with apertures 382 of thefoam 354. The retainer and foam together are then snapped around housing350 with the front wall 370 of retainer 352 positioned against frontwall 360 of housing 350, sidewalls 372 and 376 positioned adjacent tocorresponding sidewalls 362 and 366, respectively, and with partial wall378 at retainer 352 positioned against back wall 368. The retainer 352and housing 350 can be held together by way of corresponding latchmembers such as lug 390 and aperture 392 to retain the two componentstogether. This provides an easy to assemble two component intake system210 having an internal housing 350 and a retainer housing 352 wherebyair traveling through the intake system can be sound-deadened by foammember 354.

With reference now to FIG. 23, rear suspension 20 is shown removed fromthe tunnel, understanding that the rear suspension is attached to theunderside of tunnel 40. Suspension 20 includes a frame 400 havinglaterally spaced frame rails 402 with slide rails 404 attached thereto.Suspension 20 includes two coil over shocks 406 and 408 providingdampening between the tunnel 40 and frame 400. A track roller 410 ismounted on the outside of the slide rail 402, and as shown, has an outerradial surface 412 which extends beyond lower surface 414 of slider 404.Track rollers 410 are located at a position proximate a maximum pressurepoint between the sliders 404 and track (absent the track wheel) whichallows the track a slight spacing between the sliders 404 preventingsubstantial frictional heating. Suspension 20 also includes idlerrollers 420 and 422. Scratchers 426 are also provided on the side offrame 404 to break up crusted snow in order that the track can throwsnow against the underside of tunnel 40, as the tunnel includes a heatexchanger for engine water.

With reference now to FIGS. 13 and 24, a rear bumper assembly 450 isshown including a rear bumper member 452 and side brackets 454. Bumpermember 452 is comprised of a carbon fiber material and as best shown inFIG. 24 has an outer diameter 456, an inner diameter 458, and apertures460. Side brackets 454 are comprised of an extruded aluminum and includeapertures 462 for mounting the side brackets to tunnel 40 by way offasteners 464 (FIG. 13). As shown, extruded brackets 454 have extrudedopenings at 466 and apertures 468 which extend into openings 466. A cap470 is also provided having a lip 472, and a reduced diameter portion474 having apertures 476.

To assemble bumper assembly 450, bumper member 452 is positioned inopenings 466 of extruded members 454. Caps 470 are positioned withdiameter portions 474 within inner diameter 458 and with the lips 472against the extruded side bracket 454, with apertures 460 and 476aligned. Fasteners 480 are then placed through the extruded members 454,bumper member 452 and cap 470 to retain the bumper member thereto.Fasteners 464 could be set screws, bolts, rivets or any similarfastening device, although as shown, fasteners 480 are rivets. As alsoshown in FIG. 13, snow flap 34 includes a stop member 490 integrallymolded with the flap which has an upper stop surface 492 which abutsagainst the bumper member 452.

It should be generally understood that the description provided hereinrelates only to the specific embodiment, and that other variations couldbe envisions. For example, while referring herein to tubes, cylindricaltubes are shown, but it is contemplated that other structuralgeometries, such rectangular or square tubes could also be used.

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. A frame for a snowmobile comprising: a pluralityof frame members; and a coupling to receive the plurality of framemembers, the coupling includes a first open channel and a second openchannel and at least one cylindrical member for receiving the pluralityof frame members, the coupling being operatively coupled to a lowerportion of a steering post of a steering assembly, wherein aforward-most end of the at least one cylindrical member of the couplingis positioned forward of a forward-most end of the lower portion of thesteering post, and the steering assembly is mounted to the coupling at asubstantially upright angle.
 2. The frame of claim 1, wherein thesteering assembly includes the steering post operatively coupled to atleast one web of the coupling.
 3. The frame of claim 2, wherein thesteering assembly is coupled to the coupling at an angle between 0-15degrees.
 4. The frame of claim 1, wherein the coupling includes a tabfor mounting a fuel tank to the coupling.
 5. The frame of claim 4,wherein the tab is integral with the coupling.
 6. The frame of claim 1,wherein each of the frame members is attached to the coupling with atleast one of adhesive and fasteners.
 7. The frame of claim 1, wherein atleast a portion of one of the first and second open channels isvertically aligned with a portion of the at least one cylindricalmember.
 8. A connector for a snowmobile comprising: a coupling memberhaving a frame portion for securing a plurality of frame members theretoand a steering portion for coupling a steering assembly thereto, theframe portion including a first channel, a second channel, a firstcylindrical member, and a second cylindrical member for receiving theplurality of frame members, the first channel including an upper portionhaving a first upper-most surface and a lower portion, and the secondchannel including an upper portion having a second upper-most surfaceand a lower portion; and the steering portion including a first web anda second web for receiving a steering post of a steering assembly, thefirst web including an upper-most surface directly coupled to the firstupper-most surface of the first channel and the second upper-mostsurface of the second channel such that the upper-most surfaces of thefirst web, the first channel, and the second channel define a continuousouter surface of the upper portion of the coupling member, and thesecond web extending between the lower portion of the first channel andthe lower portion of the second channel.
 9. The connector of claim 8,wherein a first axis of the first channel is intersected by a first axisof the first cylindrical member and a second axis of the second channelis intersected by a second axis of the second cylindrical member. 10.The connector of claim 8, wherein the steering post is operativelycoupled to a back face of the first web and a back face of the secondweb between 0-15 degrees.
 11. The connector of claim 8, furthercomprising a tab for mounting a fuel tank to the connector.
 12. Theconnector of claim 8, wherein the first web is vertically aligned withrearwards ends of the first and second cylindrical members.